U.S. patent number 10,598,365 [Application Number 15/894,349] was granted by the patent office on 2020-03-24 for proximity sensor switched automotive lamp comprising an electrode to sense an electric field through the sensing location from the facing surface of a lens.
This patent grant is currently assigned to GRAKON, LLC. The grantee listed for this patent is Grakon, LLC. Invention is credited to Steven P. Freeder, Paul J. Jensen.
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United States Patent |
10,598,365 |
Jensen , et al. |
March 24, 2020 |
Proximity sensor switched automotive lamp comprising an electrode
to sense an electric field through the sensing location from the
facing surface of a lens
Abstract
A lamp that includes a lens, an electrode, and a sensing circuit
connected to a light source. The lens is spaced apart from the
sensing circuit. The forward facing surface of the lens has a
sensing location. The electrode has a first portion opposite a
second portion. The first portion is connected to the sensing
circuit. The second portion is positioned alongside a backward
facing surface of the lens. The electrode senses an electric field
through the lens at the sensing location. The sensing circuit is
configured to turn on the light source when the light source is
turned off and the electrode senses the electric field. The sensing
circuit is configured to turn off the light source when the light
source is turned on and the electrode senses the electric
field.
Inventors: |
Jensen; Paul J. (Seatac,
WA), Freeder; Steven P. (Renton, WA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Grakon, LLC |
Des Moines |
WA |
US |
|
|
Assignee: |
GRAKON, LLC (Des Moines,
WA)
|
Family
ID: |
67540460 |
Appl.
No.: |
15/894,349 |
Filed: |
February 12, 2018 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20190249853 A1 |
Aug 15, 2019 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F21V
31/005 (20130101); F21V 7/0066 (20130101); F21V
15/01 (20130101); B60Q 3/82 (20170201); F21V
23/0485 (20130101); F21Y 2115/10 (20160801); F21V
3/00 (20130101) |
Current International
Class: |
F21V
23/04 (20060101); F21V 7/00 (20060101); F21V
15/01 (20060101); F21V 31/00 (20060101); B60Q
3/82 (20170101); F21V 3/00 (20150101) |
Field of
Search: |
;250/221,214R |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
International Search Report and Written Opinion, dated Apr. 24,
2019, received in International Patent Application No.
PCT/US2019/015265. cited by applicant.
|
Primary Examiner: Le; Que Tan
Attorney, Agent or Firm: Blank Rome LLP
Claims
The invention claimed is:
1. A lamp comprising: a sensing circuit connected to a light
source; a lens spaced apart from the sensing circuit, the lens
comprising a forward facing surface opposite a backward facing
surface; the forward facing surface comprising a sensing location;
and an electrode having a first portion opposite a second portion,
the first portion being connected to the sensing circuit, the
second portion being positioned alongside the backward facing
surface of the lens, the electrode being configured to sense an
electric field through the lens at the sensing location, the
sensing circuit being configured to turn on the light source when
the light source is turned off and the electrode senses the
electric field.
2. The lamp of claim 1, further comprising: a reflector positioned
between the lens and the sensing circuit, the reflector being
configured to direct light from the light source when the light
source is turned on.
3. The lamp of claim 2, wherein the reflector comprises an opening,
the electrode extends through the opening in the reflector, and the
lamp further comprises: a support grommet configured to be received
inside the opening, the support grommet comprising a
through-channel, a lens facing side, and a reflector facing side,
the electrode extending through the through-channel from the
reflector facing side to the lens facing side, the electrode
comprising a bend configured to position the second portion of the
electrode against the lens facing side, the support grommet being
configured to bias the second portion of the electrode against the
backward facing surface of the lens.
4. The lamp of claim 3, wherein the support grommet is compressed
between the lens and the reflector, and the support grommet exerts
elastic pressure against the second portion of the electrode that
biases the second portion of the electrode against the backward
facing surface of the lens.
5. The lamp of claim 3, wherein the support grommet is constructed
from an electrically non-conductive material, and the reflector is
constructed from an electrically conductive material.
6. The lamp of claim 2, wherein the light source comprises a
plurality of light emitting diodes, and the reflector comprises a
plurality of reflecting portions each configured to direct light
received from one or more of the plurality of light emitting diodes
when the light source is turned on.
7. The lamp of claim 1, further comprising: a printed circuit board
upon which the sensing circuit is mounted, the first portion of the
electrode being soldered to a solder pad mounted on the printed
circuit board, the solder pad being in electrical communication
with the sensing circuit.
8. The lamp of claim 7, further comprising: a housing having a
hollowing interior configured to house the printed circuit board,
the light source, and the electrode, the lens being coupled to the
housing and closing the interior, together the lens and the housing
defining an enclosure without any openings through which a liquid
or debris may enter the interior.
9. The lamp of claim 1, wherein the electrode is constructed from a
flexible metal.
10. The lamp of claim 1, wherein the second portion of the
electrode has an area of 15 mm.sup.2 to 50 mm.sup.2.
11. The lamp of claim 1, wherein the lens is free of through-holes
and prevents liquids and debris from entering the lamp.
12. A method of constructing a lamp, the method comprising:
soldering an electrode to a solder pad mounted on a printed circuit
board, the printed circuit board comprising a sensing circuit
connected to the solder pad and one or more light emitting diodes,
the solder pad being in electrical communication with the sensing
circuit; positioning the printed circuit board inside an interior
of a housing, a free end portion of the electrode extending from
the solder pad on the printed circuit board toward a front opening
of the housing; inserting a reflector into the front opening, the
free end portion of the electrode extending through an opening in
the reflector; feeding the free end portion of the electrode
through a channel formed in a support grommet; positioning the
support grommet inside the opening formed in the reflector; and
attaching a lens to the front opening of the housing, the lens
bending the free end portion of the electrode to position a sensing
portion of the electrode alongside a front facing side of the
support grommet, the sensing portion of the electrode being
positioned alongside a backward facing surface of the lens, a front
facing surface of the lens opposite the sensing portion of the
electrode being a sensing portion, the sensing portion of the
electrode being configured to sense an electric field through the
lens, the sensing circuit being configured to turn on the one or
more light emitting diodes when the one or more light emitting
diodes are turned off and the electrode senses the electric
field.
13. The method of claim 12, further comprising: inserting a
terminal set into plated through-holes formed in the printed
circuit board, the plated through-holes being in electrical
communication with the sensing circuit, the terminal set being
configured to supply power to the sensing circuit via the plated
through-holes.
14. The method of claim 13, further comprising: inserting the
terminal set through channels formed in the housing, the channels
opening up into a first connector configured to mate with a second
connector.
15. The method of claim 12, further comprising: inserting an anchor
portion of the electrode into a through-hole formed in the printed
circuit board before the electrode is soldered to the solder
pad.
16. A lamp comprising: a lens with a rear facing surface; an
electrode having a sensing portion spaced apart from an anchor
portion, the sensing portion being pressed against the rear facing
surface of the lens; and a sensing circuit connected to a light
source, the anchor portion of the electrode being in electrical
communication with the sensing circuit, the electrode being
configured to sense an electric field through the lens, the sensing
circuit being configured to turn on the light source when the light
source is turned off and the electrode senses the electric field,
the sensing circuit being configured to turn off the light source
when the light source is turned on and the electrode senses the
electric field.
17. The lamp of claim 16, further comprising: a support grommet
configured to bias the sensing portion of the electrode against the
rear facing surface of the lens.
18. The lamp of claim 16, further comprising: a reflector
positioned between the lens and the sensing circuit, the reflector
being configured to direct light from the light source when the
light source is turned on, the reflector and the electrode each
being constructed from an electrically conductive material; and a
support grommet configured to bias the sensing portion of the
electrode against the rear facing surface of the lens, the support
grommet being constructed from an electrically non-conductive
material, the support grommet being positioned between the
electrode and the reflector to insulate the electrode from the
reflector.
19. The lamp of claim 18, wherein the reflector comprises an
opening, a channel portion of the support grommet is positioned
inside the opening, the channel portion of the support grommet has
a through-channel formed therein, and the electrode extends through
the through-channel.
20. The lamp of claim 19, wherein the support grommet has a biasing
portion connected to the channel portion, the biasing portion is
positioned between the reflector and the lens, the sensing portion
of the electrode is positioned alongside the biasing portion of the
support grommet, and the biasing portion of the support grommet
biases the sensing portion of the electrode against the rear facing
surface of the lens.
Description
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention is directed generally toward vehicle lighting
and more particularly toward interior automotive lamps operable by
a human user (e.g., a driver, a passenger, and the like).
Description of the Related Art
Interior automotive lamps allow an occupant of a vehicle to see the
inside of the passenger compartment when it is dark outside the
vehicle. Unfortunately, such lamps are generally operated by
mechanical switches that have many drawbacks. For example,
mechanical switches require features (e.g., buttons) configured to
be pressed or otherwise manually operated by the occupant of the
vehicle. Implementing these features often requires that one or
more openings be formed in the lamp. Unfortunately, such openings
may allow materials (e.g., liquids and/or debris) to enter the lamp
where such materials can interfere with the functioning of the
lamp. Therefore, a need exists for a lamp configured to be operated
without a mechanical switch. A lamp that does not include any
openings through which liquids and/or debris may enter the lamp is
particularly desirable. The present application provides these and
other advantages as will be apparent from the following detailed
description and accompanying figures.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
FIG. 1 is a perspective view of a lamp (with a capacitive proximity
switch) installed in an interior space of a vehicle.
FIG. 2 is a front perspective view of the lamp of FIG. 1.
FIG. 3 is a cross-sectional view of the lamp taken through a line
3-3 depicted in FIG. 2.
FIG. 4 is an exploded front perspective view of the lamp of FIG.
1.
FIG. 5 is a rear perspective view of a lens of the lamp of FIG.
1.
FIG. 6 is a front perspective view of a housing of the lamp of FIG.
1.
FIG. 7 is a rear perspective view of the housing of FIG. 6.
FIG. 8 is a partial side perspective view of the lamp of FIG.
1.
FIG. 9 is an exploded front perspective view of the capacitive
proximity switch of the lamp of FIG. 1.
FIG. 10 is a side perspective view of an electrode of the lamp of
FIG. 1.
FIG. 11 is a front perspective view of a support grommet of the
lamp of FIG. 1.
FIG. 12 is a rear perspective view of the support grommet of FIG.
11.
FIG. 13 is a front perspective view of a reflector of the lamp of
FIG. 1.
FIG. 14 is a rear perspective view of the reflector of FIG. 13.
FIG. 15 is a partially exploded perspective view of a pre-bent
strip used to construct the electrode and a printed circuit board
of the lamp of FIG. 1.
FIG. 16 is a front perspective view of the printed circuit board
and the strip inserted into the housing of the lamp of FIG. 1.
FIG. 17 is a top perspective view of the reflector being inserted
into the housing of the lamp of FIG. 1.
FIG. 18 is a bottom perspective view of the strip being inserted
into the support grommet of the lamp of FIG. 1.
FIG. 19 is a bottom perspective view of the lens being attached to
the housing of the lamp of FIG. 1.
FIG. 20 is a front perspective view of the lamp of FIG. 1 omitting
the lens.
FIG. 21 is a front perspective view of alternate embodiments of the
printed circuit board, the electrode, the support grommet, and the
reflector that may be used to construct the lamp of FIG. 1.
Like reference numerals have been used in the figures to identify
like components.
DETAILED DESCRIPTION OF THE INVENTION
Capacitive proximity switches have been used for many years to
provide a control interface for lamps, elevators, smart phones, and
many other appliances. Capacitance switches offer advantages over
mechanical switches. For example, capacitance switches may be more
reliable (e.g., as measured by a number of on/off cycles until
failure), have a smaller size, and allow the sensor to be triggered
through solid membranes that are impermeable to liquids, dust, and
other physical objects.
FIG. 1 depicts a light or lamp 100 configured to be installed in an
interior space 102 (e.g., a passenger compartment, a trunk, and the
like) of a vehicle 104 (e.g., a car, a truck, and the like). The
lamp 100 includes a capacitive proximity switch 108 operable by a
human user 110 (e.g., a driver, a passenger, and the like). The
capacitive proximity switch 108 is configured to sense an electric
field 112 (e.g., emitted by a finger 114 of the user 110). The
capacitive proximity switch 108 operates the lamp 100 (e.g.,
toggles the lamp 100 on and off) when the capacitive proximity
switch 108 senses the electric field 112. In other words, the lamp
100 is operated (turned on and off) without a mechanical switch or
direct physical contact between the user 110 and components of a
mechanical switch.
Referring to FIG. 4, the lamp 100 includes a cover or lens 120, a
housing 124, a substrate or printed circuit board ("PCB") 128, one
or more electrodes 132, one or more support grommets 136, a
reflector 140, a terminal set 144, and a vent patch 148. While the
lamp 100 may include more than one electrode and/or more than one
support grommet, for ease of illustration, the lamp 100 will be
described as including the single electrode 132 and the single
support grommet 136. However, through application of ordinary skill
in the art to the present teachings, embodiments may be constructed
that include two or more electrodes each like the electrode 132. In
such embodiments, a different support grommet like the support
grommet 136 may be provided for each of the electrodes.
Lens
Referring to FIGS. 2 and 3, the lens 120 is connected to the
housing 124 to form an enclosure 150. Referring to FIG. 4, the
enclosure 150 (see FIGS. 2 and 3) houses the PCB 128, the electrode
132, the support grommet 136, and the reflector 140. As will be
described below, the terminal set 144 is mounted on the PCB 128 and
extends outwardly therefrom through the housing 124.
The lens 120 is transparent and/or translucent and allows light to
shine therethrough. Referring to FIG. 3, the lens 120 may have a
generally planar front facing surface 160 opposite a back facing
surface 162. Referring to FIG. 5, a rearward extending sidewall 166
may be formed along a periphery 168 of the back facing surface 162.
A recess 170 may be formed in the back facing surface 162. Opposite
the recess 170, referring to FIG. 4, the front facing surface 160
has a remote sensing location 172. In this context, the term
"remote" refers to the position of the remote sensing location 172
with respect to the PCB 128.
Optionally, a label (e.g., a nameplate) may be positioned at or
near the remote sensing location 172. The label (not shown) may
indicate to the user 110 (see FIG. 1) where to touch the lens 120
to toggle the lamp 100 on or off.
The lens 120 may be constructed as a single continuous piece
without any through-holes formed therein (not even at the remote
sensing location 172). Thus, the lens 120 is impermeable to
liquids, dust, and dirt. In contrast, a mechanical switch cannot
include such a continuous covering. Additionally, the lack of
through-holes in the lens 120 may provide an aesthetically pleasing
appearance when compared to lamps that include buttons or other
features of conventional mechanical switches.
Housing
Referring to FIG. 6, the housing 124 has an open front portion 180
connected to a closed rear portion 182 by a sidewall 184. The rear
portion 182 and the sidewall 184 define a hollow interior 190 that
is accessible through the open front portion 180. Referring to FIG.
4, the interior 190 is configured to house the PCB 128, the
electrode 132, the support grommet 136, and the reflector 140. The
terminal set 144 is mounted on the PCB 128 and extends outwardly
therefrom through the rear portion 182 of the housing 124. The vent
patch 148 is mounted on the housing 124.
Referring to FIG. 6, the front portion 180 has a forwardly
extending sidewall 192 configured to be positioned inside the
rearward extending sidewall 166 (see FIG. 5) of the lens 120 (see
FIGS. 2-5 and 19). The sidewall 192 has an inwardly facing surface
193 opposite an outwardly facing surface 194. Friction between the
sidewall 166 and the outwardly facing surface 194 of the sidewall
192 may form a friction fit between the lens 120 (see FIGS. 2-5 and
19) and the housing 124. Optionally, referring to FIG. 4, an
adhesive may be used to attach the lens 120 to the housing 124. By
way of another non-limiting example, the lens 120 may be attached
to the housing 124 by sonic plastic welding or vibration welding.
As described below, the lens 120 may be attached to the housing 124
as the last step, which allows the lamp 100 to be sealed making it
watertight and/or dust-tight.
Referring to FIG. 6, inside the interior 190, the rear portion 182
includes one or more forwardly extending mounting pegs 196A-196H.
The mounting pegs 196G and 196H may extend further forward than the
mounting pegs 196A-196F. Optionally, the rear portion 182 may
include one or more spacers 198 configured to space the PCB 128
(see FIGS. 3, 4, 9, 15, and 16) apart from an inside surface 200 of
the rear portion 182. The rear portion 182 may include one or more
vent holes 202. The vent patch 148 (see FIGS. 3 and 4) is
configured to cover the vent hole(s) 202.
The rear portion 182 includes one or more through-channels
210A-210C and one or more stop walls 214A-214C. The stop wall(s)
214A-214C are aligned with the through-channel(s) 210A-210C,
respectively. In the embodiment illustrated in FIG. 8, the
through-channel(s) 210A-210C each extend through the inside surface
200 (see FIG. 6) and into a connector 212 formed in the rear
portion 182. The connector 212 has an opening 216 configured to
receive an electrical connector (not shown). Power may be supplied
to the lamp 100 by the electrical connector (not shown). The
electrical connector (not shown) may be configured to form a seal
with the connector 212 that prevents materials (e.g., liquids
and/or debris) from entering the interior 190 (see FIGS. 3, 4, 6,
16, and 17) through the through-channel(s) 210A-210C. The
electrical connector (not shown) may be connected to cable (not
shown) that is connected to a system (not shown) within the vehicle
104 (see FIG. 1).
Referring to FIG. 6, reflector mounting tabs 220A and 220B extend
inwardly from the sidewall 184. The reflector mounting tabs 220A
and 220B are opposite one another across the interior 190.
Optionally, the sidewall 184 may include a channel 222 that extends
along the interior 190 from the rear portion 182 to the front
portion 180.
PCB
Referring to FIG. 9, the PCB 128 has a forward facing side 230
opposite a rear facing side 232. The PCB 128 includes one or more
mounting through-holes 236A-236H. The mounting through-hole(s)
236A-236H are configured to receive the forwardly extending
mounting peg(s) 196A-196H (see FIGS. 6 and 16), respectively, of
the housing 124 (see FIGS. 2-4, 6-8, and 16-20). The mounting
peg(s) 196A-196H (see FIGS. 6 and 16) are configured to extend from
the rear facing side 232 through the mounting through-holes
236A-236H, respectively. The mounting peg(s) 196A-196F (see FIGS. 6
and 16) may be heat-staked to the PCB 128. Thus, the PCB 128 may be
non-removably attached to the housing 124 (see FIGS. 2-4, 6-8, and
16-20). The mounting peg(s) 196G and 196H (see FIGS. 6 and 16) may
be longer than the mounting peg(s) 196A-196F (see FIGS. 6 and 16)
and may extend forwardly beyond the forward facing side 230 of the
PCB 128.
The PCB 128 includes plated through-holes 244A-244C configured to
receive the terminal set 144 and form an electrical connection with
the terminal set 144. One or more electrical circuits 250 are
mounted on the PCB 128 and connected to the plated through-holes
244A-244C. The terminal set 144 provides power to the circuit(s)
250 via the plated through-holes 244A-244C.
The PCB 128 includes a through-hole or slot 246 configured to
receive the electrode 132. Thus, the electrode 132 is configured to
be physically inserted into the through-slot 246. Optionally, the
through-slot 246 may be plated. In such embodiments, the plated
through-slot 246 may be connected to the circuit(s) 250 and forms
an electrical connection between the electrode 132 and the
circuit(s) 250. Alternatively, the PCB 128 may include an
electrically conductive contact or solder pad 256 configured to be
soldered to the electrode 132. In such embodiments, the solder pad
256 is connected to the circuit(s) 250 and forms an electrical
connection between the electrode 132 and the circuit(s) 250.
The circuit(s) 250 include(s) or is/are connected to one or more
light sources 252. In the embodiment illustrated, the light
source(s) 252 has/have been implemented as six separate light
emitting diodes ("LEDs") 252A-252F mounted on the forward facing
side 230 of the PCB 128. The light source(s) 252 is/are positioned
to face forwardly so that the light generated by the light
source(s) 252 shines forwardly through the lens 120 (see FIGS. 2-5
and 19).
The circuit(s) 250 include(s) a microprocessor 254 connected to the
light source(s) 252 by conductors (not shown). By way of a
non-limiting example, the conductors (not shown) may be implemented
as conventional surface mounted traces. The microprocessor 254 may
be implemented as control chip. The electrode 132 is configured to
conduct a conductive signal to the circuit(s) 250 when the electric
field 112 (see FIGS. 1 and 3) is at or near the remote sensing
location 172 (see FIGS. 1-4 and 19). The circuit(s) 250 is/are
configured to conduct the capacitive signal between the electrode
132 and the microprocessor 254. The microprocessor 254 is
configured to detect when the capacitive signal indicates the user
110 (see FIG. 1) is touching the remote sensing location 172 (see
FIGS. 1-4 and 19). The microprocessor 254 is configured to turn on
the light source(s) 252 when the light source(s) 252 are off and
the microprocessor 254 determines the user 110 (see FIG. 1) is
touching the remote sensing location 172 (see FIGS. 1-4 and 19).
The microprocessor 254 is configured to turn off the light
source(s) 252 when the light source(s) 252 are on and the
microprocessor 254 determines the user 110 (see FIG. 1) is touching
the remote sensing location 172 (see FIGS. 1-4 and 19). In other
words, the microprocessor 254 is configured to toggle the light
source(s) 252 on and off.
Referring to FIG. 3, the electrode 132 transmits the capacitive
signal sensed by its sensing portion 280 at the remote sensing
location 172 to the microprocessor 254 inside the lamp 100. Thus,
referring to FIG. 9, the capacitive proximity switch 108 includes
the electrode 132, the circuit(s) 250, and the terminal set
144.
Optionally, the PCB 128 may include one or more reflector mounting
through-holes 260.
Electrode
The electrode 132 provides a conductive pathway between the remote
sensing location 172 (see FIGS. 1-4 and 19) and the circuit(s) 250.
Referring to FIG. 10, the electrode 132 includes a first end 270
opposite a second end 272. In the embodiment illustrated, the
electrode 132 includes first and second bends 274 and 276. The
first bend 274 defines a sensing portion 280 that extends from the
first end 270 to the first bend 274. The second bend 276 defines an
anchor portion 282 that extends from the second end 272 to the
second bend 276. An intermediate portion 284 extends between the
first and second bends 274 and 276.
Referring to FIG. 3, the intermediate portion 284 is configured to
pass through the support grommet 136 and position the sensing
portion 280 inside the recess 170 formed in the back facing surface
162 of the lens 120. The lens 120 protects the sensing portion 280,
which is sensitive to the electric field 112 (e.g., generated by
the finger 114) in its vicinity. Because the sensing portion 280 is
positioned behind the lens 120, the lamp 100 may be sealed and may
not contain through-holes through which materials (e.g., liquids
and/or debris) may enter the interior 190 of the housing 124 and
potentially damage internal components of the lamp 100.
Referring to FIG. 10, the sensing portion 280 has a front facing
surface 285 with a surface area configured such that the electric
field 112 (see FIGS. 1 and 3) of the finger 114 (see FIGS. 1 and 3)
may induce the capacitive signal in the electrode 132. The
electrode 132 conducts the capacitive signal to the circuit(s) 250
(see FIGS. 9 and 15). By way of a non-limiting example, the surface
area of the sensing portion 280 may be 15 mm.sup.2 to 50 mm.sup.2.
Referring to FIG. 3, the thickness of the lens 120 at the recess
170 (which is opposite the remote sensing location 172) is
configured to allow the electric field 112 (e.g., emitted by the
finger 114) to adequately and consistently induce the capacitive
signal in the electrode 132.
Referring to FIG. 9, the anchor portion 282 of the electrode 132 is
configured to be inserted inside the through-slot 246 of the PCB
128. Referring to FIG. 3, the intermediate portion 284 is
configured to extend away from the forward facing side 230 of the
PCB 128 toward the remote sensing location 172. The intermediate
portion 284 may extend through the channel 222 (see FIGS. 6 and 16)
formed in the housing 124. Optionally, referring to FIG. 9, a
contact portion 286 of the intermediate portion 284 adjacent the
anchor portion 282 may extend along the PCB 128 and be attached
(e.g., soldered) thereto. For example, the contact portion 286 may
be soldered to the solder pad 256 and form an electrical connection
therewith. In the embodiment illustrated, the intermediate portion
284 includes a curved portion 288 that extends from the contact
portion 286 to the first bend 274.
The electrode 132 may be constructed from metal that is easy to
solder to the solder pad 256. For example, the electrode 132 may be
constructed from thin (e.g., less than 0.15 mm) and flexible metal
(e.g., brass, bronze, and the like). Referring to FIG. 3, the
electrode 132 may be plated with a material (e.g., tin) that
facilitates soldering.
Support Grommet
Referring to FIG. 3, the support grommet 136 guides and holds the
electrode 132 as the electrode 132 passes through the reflector
140. The support grommet 136 may be constructed from an
electrically non-conductive material (e.g., silicon rubber) and the
reflector 140 may be constructed from an electrically conductive
material (e.g., metal). Thus, the support grommet 136 may insulate
the electrode 132 from the reflector 140.
The sensing portion 280 of the electrode 132 is sandwiched between
the support grommet 136 and the lens 120. Elastic pressure provided
by the support grommet 136, biases the sensing portion 280 of the
electrode 132 against the lens 120. In other words, the support
grommet 136 presses the electrode 132 against the lens 120 and
provides secure positioning of the electrode 132 with respect to
the lens 120.
Referring to FIGS. 11 and 12, the support grommet 136 has a channel
portion 300 connected to a spacer portion 302. The channel portion
300 has a front portion 304 opposite a rear portion 306. The front
portion 304 may be offset rearwardly with respect to the spacer
portion 302. The rear portion 306 includes first and second
outwardly extending stop walls 310A and 3106 configured to help
prevent the channel portion 300 from moving forwardly with respect
to the reflector 140 (see FIGS. 3, 4, 13, 14, and 17-20).
The channel portion 300 has a through-channel 312 configured to
allow the intermediate portion 284 (see FIGS. 3, 9, and 10) of the
electrode 132 (see FIGS. 3, 4, 9, 10, and 20) to pass therethrough.
The channel portion 300 extends from a front opening 314 (see FIG.
11) formed in the front portion 304 to a rear opening 316 (see FIG.
12) formed in the rear portion 306. The front opening 314 (see FIG.
11) may be larger than the rear opening 316 (see FIG. 12). Thus,
the through-channel 312 may be tapered. Referring to FIG. 11, a
curved edge portion 318 may be formed at an intersection of a lower
portion of the front opening 314 and the front portion 304.
Referring to FIGS. 11 and 12, the spacer portion 302 has a front
facing surface 320 opposite a rear facing surface 322. Referring to
FIG. 3, the sensing portion 280 of the electrode 132 is positioned
against the front facing surface 320 (see FIGS. 11 and 12). The
spacer portion 302 is compressible between the sensing portion 280
and the reflector 140. The spacer portion 302 biases the sensing
portion 280 against the lens 120. In the embodiment illustrated,
the first bend 274 may be substantially 90 degrees. Thus, referring
to FIG. 11, the through-channel 312 may extend at approximately 90
degrees with respect to the front facing surface 320.
Optionally, referring to FIG. 12, the rear facing surface 322 of
the spacer portion 302 may include a recess 324 positioned adjacent
the channel portion 300. However, this is not a requirement.
Reflector
Referring to FIG. 3, the reflector 140 is mounted inside the
interior 190 between the lens 120 and the PCB 128. Referring to
FIG. 13, in the embodiment illustrated, the reflector 140 has a
peripheral portion 330 framing a recessed portion 332. Referring to
FIG. 17, the peripheral portion 330 is configured to be positioned
adjacent the inwardly facing surface 193 of the sidewall 192 of the
housing 124.
Referring to FIG. 14, in the embodiment illustrated, the reflector
140 has rearwardly extending first and second arms 336A and 336B.
The first arm 336A has a first recess or through-hole 340A
configured to receive the first tab 220A (see FIGS. 6 and 16) and
the second arm 336B has a second recess or through-hole 340B
configured to receive the second tab 220B (see FIGS. 6, 16, and
17). Referring to FIG. 17, when the tabs 220A (see FIGS. 6 and 16)
and 220B are received inside the through-holes 340A and 340B,
respectively, the reflector 140 may be characterized as being
snapped into the housing 124.
Referring to FIG. 4, the reflector 140 has one or more rearwardly
extending mounting projections 350 each configured to be received
inside the one of the reflector mounting through-hole(s) 260 (see
FIGS. 4 and 9) of the PCB 128. The reflector 140 has rearwardly
opening apertures 352G and 352H (see FIG. 14) configured to receive
the mounting pegs 196G and 196H (see FIGS. 6 and 16), respectively,
of the housing 124 after the mounting pegs 196G and 196H have
passed through the mounting through-holes 236G and 236H (see FIG.
9), respectively, of the PCB 128.
Referring to FIG. 13, the reflector 140 has one or more light
reflecting portions 360A-360D each having a reflective sidewall 362
that extends between front and a rear openings 364 and 366. The
front opening(s) 364 are positioned within the recessed portion
332. Each of the light reflecting portion(s) 360A-360D is
positioned such that at least one of the light source(s) 252 (see
FIGS. 9 and 15) shines light through the rear opening 366 and onto
the reflective sidewall 362. In the embodiment illustrated, the LED
252A (see FIG. 9) shines light into the rear opening 366 of the
light reflecting portion 360A, the LEDs 252B and 252C (see FIG. 9)
shine light into the rear opening 366 of the light reflecting
portion 360B, the LEDs 252D and 252E (see FIG. 9) shine light into
the rear opening 366 of the light reflecting portion 360C, and the
LED 252F (see FIG. 9) shines light into the rear opening 366 of the
light reflecting portion 360D. The reflective sidewalls 362 of the
light reflecting portions 360A-360D reflect the light forwardly and
out through the lens 120 (see FIGS. 2-5 and 19). The reflective
sidewalls 362 of the light reflecting portions 360A-360D may
collimate or otherwise direct the light generated by the light
source(s) 252 (see FIGS. 9 and 15) in a desired direction. In the
embodiment illustrated, in each of the light reflecting portions
360A-360D, a reflective wall 368 extends from the reflective
sidewall 362 and into the path of the light generated by one or
more of the light source(s) 252 (see FIGS. 9 and 15). The
reflective wall 368 is configured to help direct the light in the
desired direction.
Referring to FIG. 18, the peripheral portion 330 of the reflector
140 includes a notch or opening 370 in which the channel portion
300 of the support grommet 136 may be mounted. Referring to FIG.
14, one or more sidewalls 372 may extend rearwardly alongside the
opening 370. In the embodiment illustrated, the sidewall(s) 372
include first and second sidewall portions 374A and 374B that
extend along opposite sides of the opening 370. The first and
second sidewall portions 374A and 374B may help maintain the
support grommet 136 (see FIGS. 3, 4, 11, 12, and 18-20) inside the
opening 370. Referring to FIG. 12, the first and second stop walls
310A and 3106 of the channel portion 300 of the support grommet 136
are configured to abut the first and second sidewall portions 374A
and 374B (see FIG. 14), respectively, and help prevent the channel
portion 300 from moving forwardly with respect to the reflector 140
(see FIGS. 3, 4, 13, 14, and 17-20).
Terminal Set
Referring to FIG. 9, the terminal set 144 includes two or more pins
or contacts 380A-380C. In the embodiment illustrated, the terminal
set 144 includes the three substantially identical contacts
380A-380C. One of the contacts 380A-380C may be configured to
deliver power to the circuit(s) 250, another of the contacts
380A-380C may be a ground, and the last of the contacts 380A-380C
may provide output information to the vehicle 104 (see FIG. 1). For
example, the last contact may indicate whether the lamp 100 is on
or off. The microprocessor 254 may provide the output information
to the last contact.
In the embodiment illustrated, each of the contacts 380A-380C is
generally L-shaped. Thus, the contacts 380A-380C each have first
and second legs 382 and 384 connected together by a bent portion
386. Opposite the bent portion 386, the first leg 382 has a first
free end 390. Opposite the bent portion 386, the second leg 384 has
a second free end 392.
The first legs 382 of the contacts 380A-380C are configured to
extend forwardly toward the PCB 128 along the stop walls 214A-214C
(see FIG. 6), respectively. The first free ends 390 of the contacts
380A-380C are configured to be received inside the plated
through-holes 244A-244C, respectively, and to form an electrical
connection therewith. Referring to FIG. 8, the first legs 382 of
the contacts 380A-380C are configured to extend through the
through-channels 210A-210C, respectively, to position the second
legs 384 inside the connector 212. Thus, the second free ends 392
of the contacts 380A-380C are positioned with the connector 212.
The connector 212 is configured receive the electrical connector
(e.g., a plug), which receives the second free ends 392 of the
contacts 380A-380C and forms an electrical connection therewith.
The electrical connector (not shown) may be configured to form a
seal with the connector 212 that prevents materials (e.g., liquids
and/or debris) from entering the interior 190 (see FIGS. 3, 4, 6,
16, and 17) through the through-channel(s) 210A-210C. As mentioned
above, the electrical connector (not shown) may be connected (e.g.,
via a wire) to a circuit (not shown) inside the vehicle 104 (see
FIG. 1). The circuit (not shown) in the vehicle 104 (see FIG. 1)
may include a processor (not shown) configured to receive the
indication from the last contact.
Vent Patch
Referring to FIG. 4, as mentioned above, the vent patch 148 is
configured to cover the vent hole(s) 202 (see FIGS. 3, 6, and 7)
formed in the rear portion 182 of the housing 124. In the
embodiment illustrated, the vent patch 148 is generally disk
shaped. However, this is not a requirement. The vent patch 148 may
be attached to the rear portion 182 by an adhesive. The vent patch
148 may be constructed from polytetrafluoroethylene ("PTFE") or
polyolefin.
Method
FIGS. 15-19 illustrate a method of constructing the lamp 100.
Referring to FIG. 15, the electrode 132 (see FIGS. 3, 4, 9, 10, and
20) may be constructed from a strip 400 (e.g., of metal). The strip
400 may be at least somewhat malleable so that when the strip 400
is deformed past its elastic deformation limit, the strip 400
remains bent. The strip 400 may have a simple shape (e.g., flat,
straight, and rectangular) which enables easy, low cost manufacture
compared to other more complex shapes and/or materials (e.g., a
flex circuit).
Before assembly begins, first and second bends 402 and 404 may be
formed in the strip 400. Thus, the strip 400 may be characterized
as being pre-bent, which allows the bends 402 and 404 to be formed
more accurately and faster (e.g., using hand operated jigs or
automated machinery) than they could be formed during assembly. As
shown in FIG. 15, the first bend 402 may have a smaller outside
angle (e.g., at least 30 degrees with respect to flat) than the
first bend 274 (see FIGS. 3, 9, 10, and 20) of the electrode 132
(see FIGS. 3, 4, 9, 10, and 20). By way of non-limiting examples,
the first bend 274 (see FIGS. 3, 9, 10, and 20) may have an outside
angle of approximately 90 degrees with respect to flat and the
inside angle of the first bend 402 may be at least 30 degrees with
respect to flat. Thus, the first bend 402 of the strip 400 may be
bent into the first bend 274 during the assembly process. The
second bend 404 may have an outside angle of approximately 90
degrees with respect to flat. The second bend 404 is identical to
the second bend 276 (see FIG. 10) of the electrode 132 (see FIGS.
3, 4, 9, 10, and 20).
The strip 400 has a first end 410 connected to a second end 412 by
an intermediate portion 414. After the first and second bends 402
and 404 are formed, the first end 410 is inserted into the
through-slot 246 of the PCB 128. The second bend 404 prevents the
intermediate portion 414 from slipping into or through the
through-slot 246. The second bend 404 positions the intermediate
portion 414 against the PCB 128 and into contact with the solder
pad 256 to form an electrical connection therewith. Next, the
intermediate portion 414 may be soldered to the solder pad 256. The
intermediate portion 414 may be soldered directly to the solder pad
256 without requiring a special connector of the type required to
form a connection with a flex circuit. Thus, the electrode 132 (see
FIGS. 3, 4, 9, 10, and 20) may be less expensive to implement and
easier to connect to the PCB 128 than a flex circuit. The contacts
380A-380C of the terminal set 144 may be inserted into the plated
through-holes 244A-244C, respectively, before or after the first
end 410 is inserted into the through-slot 246 of the PCB 128.
Optionally, the contacts 380A-380C of the terminal set 144 may be
soldered within the plated through-holes 244A-244C,
respectively.
Referring to FIG. 16, the PCB 128, with the strip 400 attached
thereto, is inserted into the interior 190 of the housing 124. The
mounting pegs 196A-196H are positioned within the mounting
through-holes 236A-236H (see FIG. 9), respectively. Optionally, the
mounting pegs 196A-196F may be heat-staked to the PCB 128. The
strip 400 is positioned to extend frontwardly from the PCB 128
through the channel 222 of the housing 124. Thus, as shown in FIG.
16, the strip 400 may be curved or flexed. The second legs 384 (see
FIGS. 8 and 9) of the contacts 380A-380C are positioned within the
through-channels 210A-210C (see FIGS. 6 and 8), respectively.
Referring to FIG. 17, the reflector 140 is positioned inside the
interior 190 of the housing 124. The mounting pegs 196G and 196H
(see FIGS. 6 and 16) are positioned within the apertures 352G and
352H (see FIG. 14), respectively, of the reflector 140. Each of the
mounting projection(s) 350 of the reflector 140 is positioned
inside a different one of the reflector mounting through-holes 260
(see FIGS. 4 and 9) of the PCB 128. The strip 400 is positioned
within the opening 370 formed in the peripheral portion 330 of the
reflector 140. The reflector 140 is snapped into the housing 12 by
inserting the tabs 220A and 220B (see FIGS. 6 and 16) inside the
through-holes 340A and 340B, respectively. As mentioned above, the
peripheral portion 330 is positioned adjacent the inwardly facing
surface 193 of the sidewall 192 of the housing 124.
Referring to FIG. 18, next, the first end 410 of the strip 400 is
fed into the through-channel 312 of the support grommet 136. The
first bend 402, which has not yet been bent to form the first bend
274 (see FIGS. 3, 9, 10, and 20), allows more effective
installation and positioning of the support grommet 136. The
channel portion 300 of the support grommet 136 is positioned in the
opening 370 formed in the peripheral portion 330 of the reflector
140. The rear portion 306 of the support grommet 136 is pushed into
the opening 370 far enough to position the stop walls 310A (see
FIGS. 11 and 12) and 310B against the sidewall portions 374A and
374B (see FIG. 14), respectively. The spacer portion 302 of the
support grommet 136 is positioned against the reflector 140.
Referring to FIG. 19, finally, the lens 120 is attached to the
housing 124, which bends the strip 400 toward the spacer portion
302 of the support grommet 136 along the first bend 402. Referring
to FIG. 20, this finishes forming the first bend 274 and completes
the construction of the electrode 132. The lens 120 also compresses
the support grommet 136 against the reflector 140. Referring to
FIG. 3, the sensing portion 280 is positioned inside the recess 170
formed in the back facing surface 162 of the lens 120. Thus, the
sensing portion 280 faces forwardly and is positioned on the
opposite side of the lens 120 from the remote sensing portion 172.
As mentioned above, the lens 120 may be sonic plastic welded or
vibration welded to the housing 124. The vent patch 148 may be
attached to the housing 124 to cover the vent hole(s) 202 at any
point during the assembly process.
At this point, assembly of the lamp 100 is complete. The
flexibility of the electrode 132 allows the lamp 100 to be
assembled even when there is variation in a distance between the
PCB 128 (see FIGS. 3, 4, 9, 15, and 16) and the lens 120. In
contrast, a rigid electrode may be too short or too long and could
interfere with assembly of the lens 120.
Alternate Embodiment
FIG. 21 illustrates an alternate embodiment of a PCB 128', an
electrode 132', a support grommet 136', and a reflector 140' that
may be used with the lens 120 (see FIGS. 2-5 and 19), the housing
124 (see FIGS. 2-4, 6-8, and 16-20), the terminal set 144, and the
vent patch 148 (see FIGS. 3 and 4) to construct the lamp 100.
The PCB 128' is substantially similar to the PCB 128 (see FIGS. 3,
4, 9, 15, and 16). Therefore, only differences between the PCB 128'
and the PCB 128 (see FIGS. 3, 4, 9, 15, and 16) will be described
in detail. As shown in FIG. 21, the PCB 128' differs from the PCB
128 only with respect to the location and orientation of the solder
pad 256.
The electrode 132' is substantially similar to the electrode 132
(see FIGS. 3, 4, 9, 10, and 20). Therefore, only differences
between the electrode 132' and the electrode 132 (see FIGS. 3, 4,
9, 10, and 20) will be described in detail. As shown in FIG. 21,
the electrode 132' extends from the PCB 128' and through the
reflector 140' along a substantially horizontal (front to back)
travel path. In contrast, referring to FIG. 3, the electrode 132
extends from the PCB 128 and through the reflector 140 along both a
vertical and horizontal travel path.
Referring to FIG. 21, the support grommet 136' is substantially
similar to the support grommet 136 (see FIGS. 3, 4, 11, 12, and
18-20). Therefore, only differences between the support grommet
136' and the support grommet 136 (see FIGS. 3, 4, 11, 12, and
18-20) will be described in detail. The support grommet 136' may be
implemented as a block of compressible material against with the
sensing portion 280' of the electrode 132' rests. Thus, the support
grommet 136' may omit the channel portion 300 (see FIGS. 11, 12,
and 18).
The reflector 140' is substantially similar to the reflector 140
(see FIGS. 3, 4, 13, 14, and 17-20). Therefore, only differences
between the reflector 140' and the reflector 140 (see FIGS. 3, 4,
13, 14, and 17-20) will be described in detail. In the reflector
140', an opening 370' is formed in a recessed portion 332' of the
reflector 140' instead of in a peripheral portion 330' of the
reflector 140'. Like in the reflector 140 (see FIGS. 3, 4, 13, 14,
and 17-20), the peripheral portion 330' frames the recessed portion
332'.
The foregoing described embodiments depict different components
contained within, or connected with, different other components. It
is to be understood that such depicted architectures are merely
exemplary, and that in fact many other architectures can be
implemented which achieve the same functionality. In a conceptual
sense, any arrangement of components to achieve the same
functionality is effectively "associated" such that the desired
functionality is achieved. Hence, any two components herein
combined to achieve a particular functionality can be seen as
"associated with" each other such that the desired functionality is
achieved, irrespective of architectures or intermedial components.
Likewise, any two components so associated can also be viewed as
being "operably connected," or "operably coupled," to each other to
achieve the desired functionality.
While particular embodiments of the present invention have been
shown and described, it will be obvious to those skilled in the art
that, based upon the teachings herein, changes and modifications
may be made without departing from this invention and its broader
aspects and, therefore, the appended claims are to encompass within
their scope all such changes and modifications as are within the
true spirit and scope of this invention. Furthermore, it is to be
understood that the invention is solely defined by the appended
claims. It will be understood by those within the art that, in
general, terms used herein, and especially in the appended claims
(e.g., bodies of the appended claims) are generally intended as
"open" terms (e.g., the term "including" should be interpreted as
"including but not limited to," the term "having" should be
interpreted as "having at least," the term "includes" should be
interpreted as "includes but is not limited to," etc.). It will be
further understood by those within the art that if a specific
number of an introduced claim recitation is intended, such an
intent will be explicitly recited in the claim, and in the absence
of such recitation no such intent is present. For example, as an
aid to understanding, the following appended claims may contain
usage of the introductory phrases "at least one" and "one or more"
to introduce claim recitations. However, the use of such phrases
should not be construed to imply that the introduction of a claim
recitation by the indefinite articles "a" or "an" limits any
particular claim containing such introduced claim recitation to
inventions containing only one such recitation, even when the same
claim includes the introductory phrases "one or more" or "at least
one" and indefinite articles such as "a" or "an" (e.g., "a" and/or
"an" should typically be interpreted to mean "at least one" or "one
or more"); the same holds true for the use of definite articles
used to introduce claim recitations. In addition, even if a
specific number of an introduced claim recitation is explicitly
recited, those skilled in the art will recognize that such
recitation should typically be interpreted to mean at least the
recited number (e.g., the bare recitation of "two recitations,"
without other modifiers, typically means at least two recitations,
or two or more recitations).
Accordingly, the invention is not limited except as by the appended
claims.
* * * * *